Apparatus for and method of operating on container constructions

ABSTRACT

A supporting structure is provided having a pair of wheels each supported thereon about an associated axis of rotation and each of the wheels has a plurality of die halves provided thereon. The wheels are rotated by a drive in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to operate on a container construction. Mechanical cam means is provided and holds the die halves of each set against opposite sides of an associated container construction over an angular increment enabling a fluid under pressure to be supplied through one of the die halves during such angular increment to operate on the associated container construction.

United States Patent Brunner et al. July 4, 1972 [54] APPARATUS FOR AND METHOD OF 1,478,998 1/1924 Howard et a1 .1 13 1 R OPERATING ON CONTAINER 3,380,272 4/1968 Halter ..72/ CONSTRUCTIONS FOREIGN PATENTS OR APPLICATIONS [72] Inventors: l-lans A. Brunner, Chester; Geroge B.

Volcker Hopewel" both of va- 2l0,398 1/1967 Sweden .83/326 [73] Assignee: Reynolds Metals Company, Richmond, Primary ExaminerRichard J. Herbs! Va- Attorney-G1enn, Palmer, Lyne, Gibbs & Thompson 2 F1 d: [2 ie Oct 19 1970 ABSTRACT [21] App1.No.: 81,740

A supporting structure IS provided having a pair of wheels each supported thereon about an associated axis of rotation [52} US. Cl ..72/57, 53/184, 72/191, and each of the wheels has a plurality of die halves provided 425/387 thereon. The wheels are rotated by a drive in a synchronized l at. manner so that ea h of one wheel is arranged ppogite [Sal F'eld Search "72/571601 [91? 8/19 an associated die half of the other wheel to provide a plurality 19 F1 20 R 19 R; 425/387 of cooperating sets of dies with each set being adapted to operate on a container construction. Mechanical cam means [56] Rekrems cued is provided and holds the die halves of each set against op- UNn-ED STATES PATENTS posite sides of an associated container construction over an angular Increment enabling a fluld under pressure to be sup- Clapp.....................................1 R through one 0f the haIves during such angular incre- 25481303 4/1951 "18/21 ment to operate on the associated container construction. 2,872,887 2/1959 Praturlon ....72/191 3,543,554 11/1968 Hoagland et a] ..72/191 21 Claims, 11 Drawing Figures t v 25 0 5 a f r F==m 194 o l 3; i-2 J 1 J chi A p "we. 93

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THEIR ATTORNEYS FATEHTEUJUL 4 m2 3. 673 834 SHEET 3 or 9 FIG-4 INVENTORS HANS A. BRUNNER GEORGE B. VOGELEER BY flaw/ my we 7% M4 ,7 h

THEIR ATTORNEYS PATENTEDJUL 41872 $673,834

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sum 6 or 9 FIG-7 INVENTORS HANS A. BRUNNER GEORGE B. VOGELEER a, azam THEIR ATTORNEYS INVENTORS HANS A. BRUNNER GEORGE E. VOGELEER PATENTEDJUL' 4 m2 SHEET 8 BF 9 INVENTORS HANS A. BRUNNER GEORGE B. VOGELEER BY y L1,

THEIR ATTORNEYS PATENTEDJUL 41972 SHEET 90F 9 FlG-ll INVENTORS HANS A. BRUNNER GEORGE B. VOGELEER zm m mm APPARATUS FOR AND METHOD OF OPERATING ON CONTAINER CONSTRUCTIONS BACKGROUND OF THE INVENTION In continuously operating on container constructions, such as the forming of dish-like containers from associated flat blanks, for example, it is important that cooperating die halves be moved in a positive synchronized manner and without the likelihood of slippage or misalignment therebetween. Further, in using a fluid such as high pressure air to form such dish-like containers, it is necessary that cooperating die halves be precisely moved while being held against opposite surfaces of an associated blank in a fluid-tight manner for a substantial time period to assure proper air forming.

SUMMARY This invention provides an improved apparatus for and method of operating on container constructions using a fluid as an operating medium wherein a pair of wheels are provided and mounted on an associated supporting structure with each wheel carrying a plurality of die halves. A drive is provided for rotating the wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to operate on an associated container construction. Mechanical cam meanS is provided for holding the die halves of each set against opposite surfaces of an associated container construction over an angular increment and means is provided for supplying a fluid under pressure through one of the die halves during such angular increment to operate on the associated container construction.

Other details, uses, and advantages of this invention will become apparent as the following description of the embodiment thereof presented in the accompanying drawings proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings show a present exemplary embodiment of this invention, in which FIG. I is a perspective view of a dish-like container made using the apparatus and method of this invention;

FIG. 2 is a view in elevation of one exemplary embodiment of the apparatus and method of this invention;

FIG. 3 is an end view taken on line 3--3 of FIG. 2;

FIG. 4 is a top plan view of the apparatus of FIG. 2;

FIG. 5 is an enlarged view with parts in cross-section and pans in elevation taken on the line 5-5 ofFIG. 4;

FIG. 6 is an exploded perspective view with parts broken away particularly illustrating mechanical cam means used to control the movement of die halves carried by one of the wheels of the pair of rotatable wheels comprising the apparatus of FIG. 2;

FIG. 7 is a view taken essentially on the line 7-7 of FIG. 2;

FIG. 8 is a view taken essentially on the line 8-8 of FIG. 7;

FIG. 9 is a view taken essentially on the line 9-9 of FIG. 2;

FIG. 10 is an enlarged cross-sectional view with parts broken away particularly illustrating certain portions and components of a cooperating set of die halves; and

FIG. 11 is a fragmentary view illustrating by solid lines a cooperating pair of die halves as they first engage a web of sheet material used to define a blank and illustrating by dotted lines the positions of such die halves at the completion of an angular increment during which the die halves have traveled in substantially parallel relation to enable air forming of the blank severed by such dies.

DESCRIPITON OF ILLUSTRATED EMBODIMENT Reference is now made to FIG. 2 of the drawings which i1- lustrates one exemplary embodiment of the apparatus and method of this invention and such apparatus is designated generally by the reference numeral and is particularly adapted to operate on container constructions to form associated containers. The apparatus 20 comprises a supporting structure 21 which has a lower wheel 22 and an upper wheel 23 supported on such structure so that each wheel rotates about a fixed axis of rotation 24 and 25 respectively and in this example the axes 24 and 25 are arranged horizontally and in parallel relation.

Each of the wheels has a plurality of die halves carried thereby in a manner to be described in detail subsequently and in this example the lower wheel 22 carries a plurality of female dies 26 while the upper wheel 23 carries a plurality of cooperating dies 27. As seen particularly in FIG. 3 of the drawings, a drive designated generally by the reference numeral 30 is provided for rotating the wheels 22 and 23 so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies. Each set of dies is adapted to operate on an associated container construction or flat blank, shown by dotted lines 32 in FIG. 8, in a manner to be described in detail subsequently and in this example each set is adapted to form an associated dish-like container 33 from an associated blank 32.

The apparatus 20 has unique mechanical cam means designated generally by the reference numeral 31 in FIG. 3 of the drawings and such mechanical cam means are particularly adapted to position and hold the die halves of each set against opposite surfaces or sides of an associated blank over an an gular increment A, see FIG. 8. During such angular increment and with the cooperating set of die halves held firmly in position against opposite surfaces of the associated blank, a fluid such as air under high pressure is introduced through one of the die halves, die half 27 in this example, to thereby air form the blank within the other cooperating die half 26 of the set to define a container 33 which in this example of the invention is in the form of dish-like container which has optimum structural integrity.

The dish-like container 33 is a single piece construction (see FIG. 1) which is substantially free of sharp edges at its adjoining wall portions whereby such container has optimum structural integrity. In particular, the container 33 has a bottom wall 34 which blends smoothly with a peripheral side wall 35 and such side wall has a planar flange 36 extending outwardly from a top edge 37 thereof and the flange 36 is particularly adapted to have a lid or cover sealed in position thereagainst using any suitable technique.

As seen particularly in FIGS. 3 and 4 of the drawings, the main drive for the apparatus 20 comprises a drive motor 40 (which may be an electric motor) which drives a wheel or pulley 4! using any suitable drive connection 41A such as a drive belt, drive chain, or the like, and the pulley 41 is fixed to a drive shaft 42 provided as a part of the lower wheel 22 and serves to drive such lower wheel upon rotation of shaft 42. The shaft 42 is operatively connected to a mechanical drive assembly 43 which includes a lower right angle spiral bevel gear drive 44 and a similar upper right angle drive 45 with the upper drive being operatively connected to another drive shaft 46 which is provided as a part of the upper wheel 23 and serves to drive such upper wheel.

The right angle drives 44 and 45 have a mechanical connection 47 therebetween, see FIGS. 2 and 7, which include a suitably supported roughly H-shaped key 50. The key 50 allows limited axial movement of drives 44 and 45 toward and away from each other and also compensates for any misalignment between the vertically extending shaft portions of drives 44 and 45 to assure that upon rotating the drive shaft 42 for the lower wheel 22 the shalt 46 and the upper wheel 23 are simultaneously driven in a synchronized manner.

The drive 30 rotates the wheels 22 and 23 and their as sociated forming dies in a precisely synchronized manner and the speed of the drive motor 40 is adjustable to thereby enable the precise forming of dish-like containers 33 in quantities ranging between roughly and 300 containers per minute and even greater quantities. At these high rates of production, it is well known that it is impossible to form containers of similar quality in an efficient and economical manner using reciprocating type forming machines in current use.

The exemplary apparatus is used to form containers 33 made of metallic foil, such as metallic foil containing aluminum, and a sheet or web W of such foil is provided in the form of a supply roll 50 thereof which has a central shaft 51 provided with opposite ends which are rotatably supported on spaced supports 52 carried by the supporting structure 21, see FIG. 2, and the shaft 51 has a sprocket wheel 53 suitably keyed thereto.

The supporting structure 21 ha an air brake and overrunning clutch assembly 54 suitably mounted thereon and such assembly has a shaft 55 which has another sprocket wheel 56 keyed thereto. A sprocket chain 57 extends between the sprocket wheels 53 and 56 and thus operatively connects the supply roll 50 so that its rotation is controlled by the assembly 54. The assembly 54 serves as an overrunning clutch as mentioned above and is adjustable to control the tension under which the web W of metallic foil is unwound from the supply roll 50. In addition, in the event of breakage of the web W during unwinding or once a supply roll has been exhausted the assembly 54 serves to stop rotation of the shaft 51.

The apparatus 20 has a pull roll assembly 60 which unwinds the web of metallic foil from its supply roll 50 and feeds it to the cooperating forming wheels 22 and 23. The assembly 60 comprises a lower driving roll 61 and an upper driven roll 62.

The upper roll 62 of this example has a steel cylindrical surface 63, see FIG. 5, and is spring loaded upwardly by a pair of compression springs 64. The upper roll has a pair of flange bearings 62A fixed to its opposite ends and a pair of air cylinders 65 is provided and each cylinder has a telescoping assem bly 66 extending outwardly therefrom. The telescoping assem blies 66 engage bearings 62A and override the action of the springs 64 to urge the top roll 62 toward the bottom roll 61 compressing the metallic foil therebetween under controlled pressure. The air cylinders 65 are suitably interconnected so that they exert an equal force and an adjustable air pressure regulator may be provided to assure precise control of the air pressure acting against each air cylinder 65 and hence the force exerted thereby.

The assembly 60 is also provided with a coupling device 72 connected to one end portion of the shafts for rolls 61 and 62. The coupling device 72 is of known construction and assures such rolls are rotated simultaneously in a synchronized manner to prevent slippage and assure proper movement of the web W therebetween.

The lower roll 61 has a friction surface defined by an outer sleeve 67 made of an elastomeric material such as rubber, for example. The lower roll 61 also has a sprocket wheel 73 suitably fixed to the end thereof which is arranged opposite from the device 72 and the sprocket wheel 73 may be separately driven using a separate motor, for example, and may be used for threading the web through the apparatus 20 during initial starting thereof. The gear 73 may also be driven by a chain drive (not shown) operatively connected to the main drive for the apparatus 20 to provide controlled unwinding of the Web W from the supply roll 50.

During operation of the apparatus 20, the pull roll assembly 60 feeds the web W of metallic foil to the rotating wheels 22 and 23 and the air pressure supplied to the air cylinders 65 serves to flatten and straighten such web. Once the apparatus 20 is stopped the air pressure to the cylinders 65 is also removed allowing springs 64 to urge the roll 62 upwardly and away from the web W and roll 61 whereby the Web W may be easily initially threaded through the apparatus 20.

The web W is passed between the wheels 22 and 23 where the containers 33 are formed by first punching the substantially rectangular or oval blanks 32 therefrom and each punched blank is formed to define an associated single piece container 33. The punched web continues through the apparatus 20, as illustrated at 75 in FIG. 4, and is pulled through the machine by a pair of cooperating knurled rolls 76 and 77.

As seen in FIGS. 3 and 4, the shaft 42 also has a sprocket wheel 80 suitably keyed thereto which is used to drive the front knurled roll 76 through the use of another sprocket wheel 81 keyed to a shaft 82 comprising the front roll 76 and a sprocket chain 83 which extends around wheels and 81. The other knurled roll 77 is driven by a gear 84 which is fixed to a shaft extending from roll 77 and the gear 84 meshes with a cooperating gear fixed on the driven shaft 82.

The punched web is moved by the knurled rolls 76 and 77 away from the forming wheels 22 and 23 and to a cutting or shearing roll assembly indicated generally by the reference numeral 85 in FIG. 2 of the drawings. The assembly 85 is com prised of a pair of shearing rolls 86 and 87 and a sprocket wheel 88, see FIG. 3, is provided for driving assembly 85 and is suitably keyed to a central shaft 91 extending from shearing roll 86.

The sprocket wheel 88 is driven by a chain 90 which is in turn driven by another sprocket wheel 89 fixed to the shaft 82 for the knurled roll 76. The other shearing roll 87 is driven by a gear 93 fixed to the shaft 91 which meshes with another gear 94 which is fixed to a shaft 95 extending from the shearing roll 87.

Thus, it is seen that the punched web is moved by the knurled rolls 76 and 77 to the shearing roll assembly 85 where it is sheared or shredded and the resultant scrap drops by gravity into a suitable receptacle or conveying means, as indicated by the arrow at 96, and moved away from the apparatus 20.

Each of the rotatable wheels 22 and 23 has a central hub or turret which in each instance will be designated generally by the reference numeral and each die half 26 and 27 is carried on an associated hub 100 in a substantially identical manner and using substantially identical mechanical connections. Accordingly, the detailed description will now proceed with a description of the hub 100 associated with the lower wheel 22 and a set of component parts used to support one typical forming die together with mechanical cam means used in association therewith; however, it will be appreciated that substantially identical component parts and cam means are used with the upper wheel 23 whereby the description which follows is fully applicable to both wheels 22 and 23.

Because each wheel 22 and 23 of this example carries a plurality of five die halves, each hub 100 has a pentagonal configuration, see FIG. 6. The hub 100 is fixed to its associated shaft 42 so that upon rotation of such shaft the hub together with die halves 26 will be rotated therewith. The hub 100 has a plurality of guide blocks 101 fixed thereto and the guide blocks are arranged in cooperating sets or pairs. The guide blocks in each pair are fixed in parallel relation and substantially perpendicular to one of the pentagonal sides of the hub 100 and each guide block 101 has a cutout 102 provided therein.

A roughly T-shaped supporting member 103 is provided and has a central or vertical support leg 104 which is supported for sliding movement within a bearing member 105 fixed to the hub 100. The member 103 has a horizontal arm provided with opposite end portions 106 which are slidably supported within the cutouts 102 and each end portion 106 carries a rotatable cam roller 107. The central portion of the horizontal arm of the T-shaped member 103 has a lug 110 provided with an opening 11 therethrough which is arranged parallel to the longitudinal axis of the horizontal arm portion of member 103 and the associated forming die 26 has a lower portion provided with a pair of downwardly extending flanges which extend on opposite sides of the lug 110. The flanges 112 have aligned openings 1 13 extending therethrough which enable the openlngs 111 and 113 to be an'anged in aligned relation to receive a pin 114 which pivotally supports the associated forming die 26.

The apparatus 20 includes mechanical cam means for positioning and holding the die halves of each set against Opposite sides of an associated blank 32 in a manner to be subsequently described and such mechanical cam means includes a pair of fixed cams 115 associated with each wheel 22 or 23 and the cams 115 are arranged on opposite sides of an associated hub 100. Each cam has cooperating internal surfaces defining an internal cam groove 116 which extends in an endless path and is adapted to receive an associated cam roller 107 therewithin and each cam 115 also has an outside cam surface 120.

Each fomiing die half or die 26 and 27 has a pair of cam rollers 117 rotatably supported in spaced apart aligned relation from one end portion thereof and each cam roller 1 17 rolls on the outside cam surface 120 of an associated cam 115. During rotation of each fomiing wheel and its hub 100, each associated forming die is precisely controlled by its cam rollers 107 and 117 engaging grooves 116 and surfaces 120 respectively of its associated cams 115 causing reciprocating rectilinear movement of the die toward and away from the axis of its hub 100 as indicated by the double arrow 121. Simultaneously with this reciprocating movement which is controlled by the configuration of the cam groove 116, the forming die (26 in this presentation) is pivoted about its pivot pin 114 by each of its rollers 117 engaging the cam surface 120 of an associated earn 115.

To further assure that each forming die is precisely controlled by an associated set of fixed cams 115, urging means in the form of at least one mechanical tension spring 122, see FIG. 8, is provided in operative association with each die. Each spring 122 has one end suitably attached to an car 123 extending from the lower portion of an associated die and each spring 122 has its opposite end fixed to a projection fixed to the guideblock structure which is in turn fixed to hub 100. Thus, each die half or die is pivoted by a spring 122 so that its cam rollers 117 are always held in firm contact with cam surfaces 120 whereby the pivoting movement of each die (26 or 27) about its pivot pin 114 is precisely controlled by its as sociated cam surfaces 120.

The construction and arrangement of the cam grooves 116 and the outside cam surfaces 120 in this example is such that each cooperating set of die halves 26 and 27 are precisely positioned so that their outside surfaces are arranged in parallel relation and against opposite surfaces of the web W fed through the apparatus 20 25 before reaching what will be referred to as dead center, i.e., the position where a set of cooperating dies 26 and 27 have their outside web-engaging surfaces arranged horizontally and a central axis perpendicular to such web-engaging surfaces is arranged substantially vertically, and will be designated by the reference numeral 125.

Each cooperating set of dies 26 and 27 are held together by the mechanical cams 115 for 25 past dead center or the vertical axis 125 and during this total angular travel of 50 (which will be referred to as angular increment A) the dies travel in a straight line. However, it is common knowledge that a point or object being rotated about an axis of rotation normally travels in a circle and thus in an arcuate path over an angular increment of such circle. Therefore, it is necessary that the cooperating action of the cam grooves 116 and cam surfaces 120 provide precisely controlled movement of the hinge pin 114, and hence the associated die half, so that it moves gradually toward the central axis of its associated hub 100 for the first 25 of movement until it reaches dead center and the hinge pin 114 must then move gradually away from the central axis of the hub 100 for the next 25 degrees of movement. This is achieved as illustrated particularly in FIG. 6 of the drawings by providing a unique arcuate section 126 in each cam groove 116 which is particularly adapted to receive an associated cam roller 107 therewithin and provides movement of its cam roller 107 toward the center of its hub 100 through the 25 angular increment 127 and then gradually away from the center of the hub 100 through the 25 angular increment 128.

Thus, it is seen that the above-described mechanical cam means holds the die halves of each set against opposite surfaces of an associated blank over an angular increment of fifty degrees and causes such die halves to move in a straight line. During this movement of the die halves, the web W may also be moved so that the velocity thereof through the apparatus 20 is equal to the straight line velocity of the cooperating die halves.

As a cooperating set of dies 26 and 27 move into engagement against opposite surfaces of the web W, they automatically shear a blank 32, see FIGS. 8-10, which is then fonned using a fluid, such as air, under pressure and with the wheels 22 and 23 rotating continuously in particular, as a cooperating set of die halves 26 and 27 are brought together, the blank 32 is sheared by the action of a peripheral annular plate in the upper die half 27 as will now be explained.

The lower die 26 has a centrAl member 131 which is supported for limited movement by a plurality of bolts 129. Each bolt 129 has a compression spring 132 supported therearound which acts between a lower portion 133 of the die 26 and the member 131 to thereby yieldingly urge the member 131 outwardly. The springs 132 may be compressed allowing member 131 to be moved or nested within member 133 a distance indicated at 134 to thereby expose an inner cutting edge 135 of an annular member 136 fixed to the lower member 133 so that a cutting edge 137 provided on the member 130 cooperates with edge 135 to shear a blank 32 from the web W.

The blank is clamped and held between annular planar surfaces 140 and 141 of members 130 and 131 respectively of upper die 27 and lower die 26 during the entire 50 angular increment A. Once a cooperating set of forming dies 26 and 27 are moved apart at the end ofthe 50 angular increment, it will be appreciated that the compression springs 132 will return member 131 of an associated lower forming die 26 outwardly. In addition, an annular stripper 142 is provided around the member 130 and is supported in position for limited axial movement by a plurality of bolts 143. A compression spring 144 is provided around each bolt 143 and the springs yieldingly urge stripper 142 outwardly in a known manner and strip the punched web from member 130 and hence from the associated upper die 27.

Having described the manner in which each cooperating set of dies 26 and 27 are moved and held together so they travel in a straight line over the angular increment A while shearing an associated blank 32 from the web W, the detailed description will now proceed with a description of the manner in which high pressure air is used to form such blank and define an associated dish-like container 33. Air under regulated preS- sure is introduced into the upper dies 27 through a plurality of valves 146 and each valve 146 has an axially movable spool 147 provided with a plunger 148 fixed thereto which telescopes through the valve housing 150. The housing 150 has a pair of ports 151 and 152 provided therein and air flow through such ports is controlled by the position of the spool 147 which is normally urged to prevent air flow out of valve 146 by a compression spring 153.

Air under pressure is provided from any suitable source through a line 154 which communicateswith port 151 and a flexible line 155 extends between port 152 and a passage 156 in die 27 which terminates in a central outlet orifice 157. During the greater portion of each revolution of wheel 23 the spring 153 urges spool 147 so that is covers port 152, as shown at 158 in FIG. 8, whereupon air under pressure cannot be provided out of valve 146. As the upper die 26 moves to its top dead center position, the plunger 148 engages an associated surface 160 of the hub 100, causing the compression spring 153 to be overridden and the spool 147 to be moved away from port 152 allowing high pressure air to be supplied through line 155, passage 156, and orifice 1S7 allowing air forming of the blank 32 to the configuration of a die cavity 162 provided in the lower die 26. The lower die 26 has passage means shown as a plurality of openings 163 therein which allow escape of air which would ordinarily be trapped between the formed blank, now container 33, and the surface defining cavity 162. The air flowing through openings 163 moves into a central recess 164 in the die 26 and is suitably bled from such recess.

During the air forming of containers 33 the forming action is preferably accomplished over the substantial angular incre ment A to assure proper forming. The unique construction of the cooperating dies 26 and 27, and the associated mechanical cam means assure that the forming may be achieved in a continuous manner during rotation of the wheels 22 and 23 and without requiring indexing movements or stoppage of such wheels.

The apparatus also has a plurality of valves carried by the lower wheel 22 and inasmuch as such valves are very similar to valves 146 each of such valves will also be designated generally by the reference numeral 146 and its component portions given identical reference numerals as previously and not described again in detail.

As air under pressure is released in an upper die 27 to form a container 33, the valve 146 in the associated lower die 26 is closed because the sleeve 147 is positioned over port 152. As the die halves 26 and 27 move to the position indicated at 165 in FIG. 8, the formed container 33 is held in cavity 162 by partial vacuum and the valve 146 at position 165 is still held closed by the spring 153 holding sleeve 147 between ports 151 and 152. Once the die 26 reaches its lowermost position or ejection station at 166, plunger 148 engages a cam surface 167 causing movement of sleeve 147 so that air under pressure can flow through lines 154 and 155 to forcefully eject the container 33 from die cavity 162.

The apparatus 20 has an endless belt conveyor 167 for conveying completed dish-like containers 33 away therefrom. The belt conveyor 167 has a pair of rollers 168 at opposite ends thereof and a tensioning device 169 is provided for controlling the tension of such conveyor. The belt conveyor 167 may be driven independently; however, in this example such belt conveyor is driven by a sprocket wheel 170 keyed to shaft 42, see FIG. 3, and another sprocket wheel 171 keyed to the shaft for a roller 168 with a chain drive 172 extending therebetween. Thus, the belt conveyor 167 is also driven by the main drive for the apparatus 20.

Although a conveyor 167 has been shown for moving completed containers 33 away from apparatus 20, it will be appreciated that such containers may be ejected into a supply bin or hopper and then periodically moved away from wheels 22 and 23 for further processing.

To assure that the formed containers 33 are introduced onto the conveyor 167 at the proper location, an arcuate guide chute 173 is provided and helps support and guide each container that is loose in its die cavity toward the ejection station 166, see FIG. 8.

Each cooperating set of die halves of the wheels 22 and 23 is supported and precisely moved to enable shearing of an associated blank 42 from the traveling web W and then hold the peripheral edges of such blank clamped between associated clamping surfaces 140 and 141 of die halves 26 and 27 respectively. This movement and holding is made possible by providing means for precisely adjustinG the wheels relative to each other. In this example, such adjusting means comprises a pair of adjustable stops 175, each adjustably threaded within an associated structural member 176 extending outwardly from a portion of the supporting structure which supports the upper rotatable wheel 23, see FIG. 7, as will now be described.

The upper wheel 23 has its shaft 46 supported by a pair of bearing assemblies 177 and a lower portion 180 of each assembly 177 rests on an associated adjustable stop 175. A pair of air cylinders 18] is provided and each air cylinder 181 has a telescoping member 182 which engages and holds an associated bearing assembly firmly against the top surface of its associated stop. The air cylinders 181 exert sufficient pressure to assure the shaft 46 of the wheel 23 is held firmly in position during rotation of cooperating wheels 22 and 23 once the positions of their respective axes 24 and 25 have been established by adjusting stops 175. It will also be appreciated that the mechanical drive assembly 43 is constructed to allow limited movement of entire upper wheel 23 toward and away from the lower wheel 22 without disturbing the positive drive connection between such wheels.

The apparatus 20 in this example of the invention has a pair of cooperating wheels 22 and 23 each having a plurality of five die halves carried thereon and provided as an integral part thereof; however, it will be appreciated that the apparatus and method of this invention may be utilized with wheels having either less than five cooperating die halves or more than five cooperating die halves while still enabling the provision of containers 33 in a continuous manner during rotation of such wheels and in a similar manner as described for the apparatus 20.

The apparatus 20 may be suitably modified to enable the use of a fluid under pressure to form containers having shapes other than a dish-like shape. For example, modified apparatus may be provided to form either shallower or deeper containers.

The apparatus 20 may be suitably modified to also enable embossing of container walls, heat sealing or otherwise attaching lids over open-ended containers and similar operations; therefore, it is to be understood that the term operating on used in certain of the claims presented herein is intended to cover operating on a workpiece or container construction to form, shape, emboss, seal, and other similar operations.

The wheels 22 and 23 may be interchanged so that the die halves containing the female die cavities are provided as a portion of the upper wheel and the means providing air under pressure for forming may be provided as a portion of the lower wheel. it will also be appreciated that the wheels 22 and 23 may be arranged in any suitable manner, as with their parallel axes arranged vertically, for example.

in this presentation of the invention the roll of sheet material used in forming containers 33 has been provided as a roll of metallic foil. However, it will be appreciated that any other suitable material may be used to form containers in a similar manner and using a fluid under pressure. In particular, a web W of thermoplastic material may be used and either one or both of the dies of each cooperating set may be suitably heated during the application of air under pressure to enable forming of an associated plastic container. Further, instead of using air under pressure a hot fluid such as steam may be used to simultaneously provide the shaping action as well as heat the thermoplastic material to enable plastic flow and easier forming.

While present exemplary embodiments of this invention, and methods of practicing the same, have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced within the scope of the following claims.

What is claimed is:

1. An apparatus for operating on container constructions comprising, a supporting structure, a pair of wheels each supported on said structure about an associated fixed central axis of rotation, each of said wheels having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to operate on a container construction, mechanical cam means position ing and holding the die halves of each set in fluid-tight engagement against opposite sides of an associated container construction over an angular increment during continuous rotation of said wheels, said mechanical cam means providing positively controlled movement of the die halves of each set in a substantially rectilinear path during said angular increment, and means supplying a fluid under pressure through one of said die halves of each set during said angular increment to operate on the associated container construction.

2. An apparatus as set forth in claim 1 in which each of the die halves on one of said wheels has a die cavity therein, each container construction comprises a flat blank which is adapted to have its peripheral edge portions clamped between a cooperating set of dies, and said supplying means supplies fluid under pressure against one side of each blank clamped between a cooperating set of dies to thereby urge the blank within an associated die cavity to define an associated container.

3. An apparatus as set forth in claim 1 and further comprising means supporting each die half for movement relative to its wheel, and said mechanical cam means comprises at least one fixed cam associated with each wheel and at least one cam roller rotatably supported on each die half, said cam roller engaging said cam to move its die half on its associated supporting means to assure its die half is positioned and held against an associated container construction over said angular increment.

4. An apparatus as set forth in claim 1 and further comprising means supporting each die half for radial inward and outward movement along a radial line extending from the center of each wheel and for pivoting movement at any radial position of each die half, said mechanical cam means comprises at least one fixed cam associated with each wheel, said cam having cooperating internal surfaces defining an internal cam groove therein which extends in an endless path and having an outside cam surface, and a pair of cam rollers rotatably supported on each die half with one of said cam rollers being received within said groove allowing said cooperating surfaces to control the radial position of its die half and the other of said cam rollers engaging said outside cam surface and controlling pivoting movement of its die half, said cam rollers and cam assuring an outside surface of its die half moves in said substantially rectilinear path over said angular increment while being held against its associated container construction.

5. An apparatus as set forth in claim 4 and further comprising a spring device urging said other cam roller against said outside cam surface to assure precise pivoting movement of the associated die half.

6. An apparatus as set forth in claim 4 in which said cam groove has an arcuate section defined by a corresponding portion of said cooperating internal surfaces, said arcuate section guiding said one cam roller and its die half for movement gradually toward the center of its wheel during rotation thereof for half of said angular increment and then gradually away from the center of its wheel during the remaining half of said angular increment.

7. An apparatus as set forth in claim I and further comprising a central shaft comprising one wheel of said pair and a pair of adjustable supports on opposite sides of said one wheel supporting said shaft and its wheel and enabling precise adjustment of the position of said one wheel relative to the other wheel.

8. An apparatus as set forth in claim 7 and further comprising a pair of bearing assemblies carried by said shaft, said bearing assemblies allowing substantially frictionless rotation of said shaft and its wheel, and a pair of fluid operated actuators each urging and holding a bearing assembly against an associated adjustable suPport.

9. An apparatus as set forth in claim 2 and further comprising means for exerting air under pressure in each die cavity to eject each formed container away from its die half.

10. An apparatus for continuously forming containers comprising, a supporting structure, a pair of wheels each supported on said structure about an associated fixed central axis of rotation, each of said wheels having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to form an associated container, mechanical cam means holding the die halves of each set in fluid-tight engagement against opposite sides of an associated flat blank over an angular increment during continuous rotation of said wheels about their central axes, said mechanical cam means providing positively controlled movement of the die halves of each set in a substantially rectilinear path during said angular increment, and a device supplying a fluid under pressure through one of said die halves during said angular increment to form an associated container from said blank.

ll. An apparatus as set forth in claim 10 and further comprising a rotatable shaft for supporting a supply roll defined by a wound web of sheet material for unwinding rotation, a pull roll assembly for unwinding said web to enable movement of said sheet material between said wheels, and cooperating cutting edges on the die halves of each set for punching said web during the initial part of said angular increment to define an associated blank.

12. An apparatus as set forth in claim 11 and further comprising an adjustable brake and over-running clutch assembly operatively connected to said rotatable shaft for controlling the tension in said sheet material during unwinding thereof and for stopping rotation of said rotatable shaft in the event of an exhausted supply roll or breakage of the sheet material.

13. An apparatus as set forth in claim 11 in which said pull roll assembly comprises a driving roll having a friction surface made of an elastomeric material, and a clamping roll yieldingly urged toward said driving roll to flatten said sheet material.

14. An apparatus as set forth in claim 13 and further comprising a pair of air cylinders yieldingly urging said clamping roll toward said driving roll in a controlled manner.

15. An apparatus as set forth in claim 11 and further comprising a device for pulling the punched web away from said wheels.

16. An apparatus as set forth in claim 11 and further comprising a shearing roll assembly for shearing the punched web.

17. An apparatus as set forth in claim 11 and further comprising means supporting each die half for radial inward and outward movement along a radial line extending from the center of each wheel and for ivoting movement at any radial position of each die half, and said mechanical cam means comprises at least one fixed cam associated with each wheel, said cam having cooperating internal surface defining an internal cam groove therein which extends in an endless path and having an outside cam surface, and a pair of cam rollers rotatably supported on each die half with one of said cam rollers being received within said groove allowing said cooperating surfaces to control the radial position of its die half and the other of said cam rollers engaging said outside cam surface and controlling pivoting movement of its die half, said cam rollers and cam assuring an outside surface of its die half moves in said substantially rectilinear path over said angular increment while being held against its blank.

18. A method of continuously forming blanks to define as sociated containers, said method comprising the steps of, continuously rotating a pair of substantially circular wheels each having a plurality of die halves in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to define a plurality of cooperating sets of die halves with the die halves of each set being adapted to form an associated blank, providing a blank between each cooperating set of die halves, positioning and holding the die halves of each set firmly in fluid-tight engagement against opposite surfaces of its associated blank using mechanical cam means and over an angular increment while rotating said wheels about fixed parallel axes, said positioning and holding step comprising moving the die halves of each set in parallel relation and in a substantially rectilinear path in a positively controlled manner using said mechanical cam means during said angular increment, and supplying air under pressure through one of the die halves of each set during said angular increment to thereby air form the associated blank and define a container.

19. A method as set forth in claim 18 in which said providing step comprising said blank made of a metallic material between each cooperating set of die halves and upon supplying air during said supplying step said blank is formed within a die cavity in a die half of the cooperating set.

20. A method as set forth in claim 18 and comprising the further step of placing a web of sheet material between said rotating wheels and severing said web using the die halves of each set to define an associated blank.

21. A method as set forth in claim 20 in which said placing step comprises pulling said web between said wheels at a con- 

1. An apparatus for operating on container constructions comprising, a supporting structure, a pair of wheels each supported on said structure about an associated fixed central axis of rotation, each of said wheels having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to operate on a container construction, mechanical cam means positioning and holding the die halves of each set in fluid-tight engagement against opposite sides of an associated container construction over an angular increment during continuous rotation of said wheels, said mechanical cam means providing positively controlled movement of the die halves of each set in a substantially rectilinear path during said angular increment, and means supplying a fluid under pressure through one of said die halves of each set during said angular increment to operate on the associated container construction.
 2. An apparatus as set forth in claim 1 in which each of the die halves on one of said wheels has a die cavity therein, each container construction comprises a flat blank which is adapted to have its peripheral edge portions clamped between a cooperating set of dies, and said supplying means supplies fluid under pressure against one side of each blank clamped between a cooperating set of dies to thereby urge the blank within an associated die cavity to define an associated container.
 3. An apparatus as set forth in claim 1 and further comprising means supporting each die half for movement relative to its wheel, and said mechanical cam means comprises at least one fixed cam associated with each wheel and at least one cam roller rotatably supported on each die half, said cam roller engaging said cam to move its die half on its associated supporting means to assure its die half is positioned and held against an associated container construction over said angular increment.
 4. An apparatus as set forth in claim 1 and further comprising means supporting each die half for radial inward and outward movement along a radial line extending from the center of each wheel and for pivoting movement at any radial position of each die half, said mechanical cam means comprises at least one fixed cam associated with each wheel, said cam having cooperating internal surfaces defining an internal cam groove therein which extends in an endless path and having an outside cam surface, and a pair of cam rollers rotatably supported on each die half with one of said cam rollers being received within said groove allowing saId cooperating surfaces to control the radial position of its die half and the other of said cam rollers engaging said outside cam surface and controlling pivoting movement of its die half, said cam rollers and cam assuring an outside surface of its die half moves in said substantially rectilinear path over said angular increment while being held against its associated container construction.
 5. An apparatus as set forth in claim 4 and further comprising a spring device urging said other cam roller against said outside cam surface to assure precise pivoting movement of the associated die half.
 6. An apparatus as set forth in claim 4 in which said cam groove has an arcuate section defined by a corresponding portion of said cooperating internal surfaces, said arcuate section guiding said one cam roller and its die half for movement gradually toward the center of its wheel during rotation thereof for half of said angular increment and then gradually away from the center of its wheel during the remaining half of said angular increment.
 7. An apparatus as set forth in claim 1 and further comprising a central shaft comprising one wheel of said pair and a pair of adjustable supports on opposite sides of said one wheel supporting said shaft and its wheel and enabling precise adjustment of the position of said one wheel relative to the other wheel.
 8. An apparatus as set forth in claim 7 and further comprising a pair of bearing assemblies carried by said shaft, said bearing assemblies allowing substantially frictionless rotation of said shaft and its wheel, and a pair of fluid operated actuators each urging and holding a bearing assembly against an associated adjustable suPport.
 9. An apparatus as set forth in claim 2 and further comprising means for exerting air under pressure in each die cavity to eject each formed container away from its die half.
 10. An apparatus for continuously forming containers comprising, a supporting structure, a pair of wheels each supported on said structure about an associated fixed central axis of rotation, each of said wheels having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to form an associated container, mechanical cam means holding the die halves of each set in fluid-tight engagement against opposite sides of an associated flat blank over an angular increment during continuous rotation of said wheels about their central axes, said mechanical cam means providing positively controlled movement of the die halves of each set in a substantially rectilinear path during said angular increment, and a device supplying a fluid under pressure through one of said die halves during said angular increment to form an associated container from said blank.
 11. An apparatus as set forth in claim 10 and further comprising a rotatable shaft for supporting a supply roll defined by a wound web of sheet material for unwinding rotation, a pull roll assembly for unwinding said web to enable movement of said sheet material between said wheels, and cooperating cutting edges on the die halves of each set for punching said web during the initial part of said angular increment to define an associated blank.
 12. An apparatus as set forth in claim 11 and further comprising an adjustable brake and over-running clutch assembly operatively connected to said rotatable shaft for controlling the tension in said sheet material during unwinding thereof and for stopping rotation of said rotatable shaft in the event of an exhausted supply roll or breakage of the sheet material.
 13. An apparatus as set forth in claim 11 in which said pull roll assembly comprises a driving roll having a friction surface made of an elastomeric material, and a clamping roll yieldingly urged toward said driving roll to flatten said sheet material.
 14. An apparatus as set forth in claim 13 and further comprising a pair of air cylinders yieldingly urging said clamping roll toward said driving roll in a controlled manner.
 15. An apparatus as set forth in claim 11 and further comprising a device for pulling the punched web away from said wheels.
 16. An apparatus as set forth in claim 11 and further comprising a shearing roll assembly for shearing the punched web.
 17. An apparatus as set forth in claim 11 and further comprising means supporting each die half for radial inward and outward movement along a radial line extending from the center of each wheel and for pivoting movement at any radial position of each die half, and said mechanical cam means comprises at least one fixed cam associated with each wheel, said cam having cooperating internal surface defining an internal cam groove therein which extends in an endless path and having an outside cam surface, and a pair of cam rollers rotatably supported on each die half with one of said cam rollers being received within said groove allowing said cooperating surfaces to control the radial position of its die half and the other of said cam rollers engaging said outside cam surface and controlling pivoting movement of its die half, said cam rollers and cam assuring an outside surface of its die half moves in said substantially rectilinear path over said angular increment while being held against its blank.
 18. A method of continuously forming blanks to define associated containers, said method comprising the steps of, continuously rotating a pair of substantially circular wheels each having a plurality of die halves in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to define a plurality of cooperating sets of die halves with the die halves of each set being adapted to form an associated blank, providing a blank between each cooperating set of die halves, positioning and holding the die halves of each set firmly in fluid-tight engagement against opposite surfaces of its associated blank using mechanical cam means and over an angular increment while rotating said wheels about fixed parallel axes, said positioning and holding step comprising moving the die halves of each set in parallel relation and in a substantially rectilinear path in a positively controlled manner using said mechanical cam means during said angular increment, and supplying air under pressure through one of the die halves of each set during said angular increment to thereby air form the associated blank and define a container.
 19. A method as set forth in claim 18 in which said providing step comprising said blank made of a metallic material between each cooperating set of die halves and upon supplying air during said supplying step said blank is formed within a die cavity in a die half of the cooperating set.
 20. A method as set forth in claim 18 and comprising the further step of placing a web of sheet material between said rotating wheels and severing said web using the die halves of each set to define an associated blank.
 21. A method as set forth in claim 20 in which said placing step comprises pulling said web between said wheels at a controlled speed and said rotating step comprises continuously rotating said wheels so that as each set of cooperating die halves moves to a position immediately preceding said angular increment each set severs an associated blank from said web. 